• When working with 2 or more persons, be sure to check safety for one another.

• When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

• If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.

• When jacking up the vehicle, be sure to support the specified location with a safety stand.

• When lifting up the vehicle, use appropriate safety equipment.

4

Preparation of tools and measuring gauge

Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement.

5

Removal and installation, disassembly and assembly operations

• Diagnose with a thorough understanding of proper procedures and of the reported problem.

• Before removing parts, check the general condition of the assembly and for deformation and damage.

• When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed.

• Clean and wash the removed parts if necessary and assemble them after a thorough check.

6

Removed parts

• Place removed parts in a separate box to avoid mixing them up with new parts or

contaminating new parts.

• For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them

with new ones as instructed in this manual.

• Retain the removed parts for customer inspection, if requested.

N D100721E01

N D100721E01

INCORRECT CORRECT

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(b) JACKING UP AND SUPPORTING VEHICLE

(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

(c) PRECOATED PARTS

(1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.

(2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.

(3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.

(4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.

(d) GASKETS

(1) When necessary, use a sealer on gaskets to prevent leaks.

(e) BOLTS, NUTS AND SCREWS

(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.

(1) When inspecting a fuse, check that the wire of the fuse is not broken.

(2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

Illustration

Symbol

Part Name

Abbreviation

N

N

FUSE

FUSE

N

N

MEDIUM CURRENT FUSE

M-FUSE

Illustration

Symbol

Part Name

Abbreviation

HIGH CURRENT FUSE

H-FUSE

N

N

FUSIBLE LINK

FL

N

N

CIRCUIT BREAKER

CB

N

N

(1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT:

If clips are damaged during a procedure, always replace the clips with new clips.

Shape (Example)

Illustration

Procedures

1. Remove clips with a clip remover or pliers.

1. Remove clips with a clip remover or screwdriver.

Shape (Example)

Illustration

Procedures

1. Remove clips with a wide scraper to prevent panel damage.

1. Remove clips by pushing the center pin through and prying out the shell.

1. Remove clips by unscrewing the center pin and prying out the shell.

1. Remove the clip by prying out the pin and then prying out the shell.

(1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT:

If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.

Shape (Example)

Illustration

Procedures c

1. Using a screwdriver, detach the claws and remove the caps or cover.

1. Using a screwdriver, detach the claws and remove the caps or cover.

1. Using a screwdriver, detach the claws and remove the caps or cover.

(i) REMOVAL AND INSTALLATION OF VACUUM HOSES

(1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.

(2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

(3) After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.

(4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.

(j) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL

L1

L2

c

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J .—:

- ~u

—j

N

D100725E01

(1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench. Formula: T = L2 / (L1 + L2) * T

T'

Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}

T

Torque {N*m (kgf*cm, ft.*lbf)}

L1

Length of SST or extension tool {cm (in.)}

L2

Length of torque wrench {cm (in.)}

NOTICE:

If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. 2. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM

The RAV4 is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following:

1. Steering pad

2. Front passenger airbag assembly

3. Front seat side airbag assembly

4. Front seat outer belt assembly with pretensioner

5. Curtain shield

6. Center airbag sensor

7. Front airbag sensor

8. Side airbag sensor

9. Rear airbag sensor 10.0ccupant Classification ECU

CAUTION:

• Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions.

• Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.)

• Do not expose SRS parts directly to hot air or flames.

NOTICE:

• Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal.

• For minor collisions where SRS parts do not deploy, always inspect the SRS parts.

• Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs.

• Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones.

• Never disassemble or attempt to repair SRS parts.

• If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one.

• Use an ohmmeter/voltmeter with high impedance (10 kQ/V minimum) for troubleshooting the electrical circuits.

• Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels.

• After work on SRS parts is completed, perform the SRS warning light check.

• When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system.

(a) SPIRAL CABLE

(1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

(b) AIRBAG ASSEMBLY

(1) Airbag assembly with pad:

Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly.

(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury.

(3) Grease or detergents of any kind should not be applied to the airbag assembly.

(4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

(6) When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

(c) SEAT OUTER BELT ASSEMBLY WITH

PRETENSIONER

(1) Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury.

(2) Never install the seat outer belt on another vehicle.

(3) Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.

(4) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring.

(5) When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise.

(6) As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt.

(7) Grease, detergents, oil or water should not be applied to the seat outer belt.

(d) AIRBAG SENSOR ASSEMBLY

(1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed.

(2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate.

(3) Work must be started at least 90 seconds after the ignition switch is turned OFF and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

(e) WIRE HARNESS AND CONNECTOR

(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

Don't pay hundreds of dollars to find out what is wrong with your car. This book is dedicated to helping the do it yourself home and independent technician understand and use OBD-II technology to diagnose and repair their own vehicles.